Membrane assembly for a three-dimensional printing system

ABSTRACT

A vat polymerization apparatus configured with a resin circulatory system that includes pumps arranged to extract used photo-curing resin from a tank and refresh or replace it with new resin, another fluid, or a combination of new resin and the fluid. Resin flow is regulated using a plurality of valves which are opened and closed to achieve a desired circulation process. Additional aspects of the apparatus include a membrane assembly in which a radiation-transparent flexible membrane is supported in a frame that stretches the membrane. A lip of the frame is secured to a bottom rim of the tank; thus, when the membrane assembly is in place it forms a bottom of the tank. A tension adjustment mechanism may be employed to adjust the tension of the membrane within the frame. The frame may be aligned with the tank with the aid of magnetized alignment aids distributed about the frame.

RELATED APPLICATIONS

This application is a Continuation Application of U.S. application Ser.No. 16/676,940, filed on 7 Nov. 2019, which is a non-provisional patentapplication of and claims priority to U.S. Provisional Application No.62/758,413, filed 9 Nov. 2018, both of which are incorporated byreference herein.

FIELD OF THE INVENTION

The present invention relates to additive manufacturing systems in whicha photo-sensitive resin within a tank is cured through exposure toradiation when fabricating an object, and in particular to resincirculatory systems, and tank and membrane assembly components of suchsystems.

BACKGROUND

Within the field of additive manufacturing, so-called three-dimensionalprinting, or 3D printing, by means of photo-curing a viscous, liquidresin (typically a liquid polymer) layer-by-layer to form a desiredobject has become very popular. In this field, two basic technologiesare employed: stereolithographic (SL) printing, in which a laser,emitting radiation at approximately 400 nm, is used to cure the liquidresin; and Digital Light Processing (DLP) printing, in which the liquidresin is exposed to the luminous radiation emitted by a device similarto a projector. A variation of DLP printing employs a light enginecomposed of one or more light emitting diodes (LEDs) that radiate in theultraviolet (UV) spectrum.

In both the SL and DLP processes, printing of the object proceedslayer-by-layer, that is, polymerizing a first layer of the liquid resinadhering to an extraction (or build) plate, polymerizing a second layeradhering to the first layer, and so on until formation of the completeobject. Data representing the three-dimensional object to be formed isorganized as a series two-dimensional layers that represent transversalsections of the object, and the build proceeds according to that design.While such builds can proceed top down, where the entire object isformed within the liquid resin and then extracted in full, the so-calledbottom-up method in which the extraction plate is raised, and the objectthereby moved from the bottom of a vat of resin upwards, layer-by-layeris more popular for small and desktop printing applications.

The polymerization process by which the liquid resin solidifies into thedesired object layers is exothermic. Perhaps because of the highlyviscous nature of the resin, at least in part, the heat generated bythis process tends to remain localized within the area in which printingoccurs—the so-called build area. This heating can be quite detrimental,especially in continuous or near-continuous printing operations, asexcessive heat in the build area will affect the quality of the layersbeing printed, e.g., by contributing to undesired curing of the resin.

Discussed herein are techniques to address the heating of the resin, aswell as other improvements to the 3D printing system.

SUMMARY OF THE INVENTION

A vat polymerization apparatus configured in accordance with oneembodiment of the invention includes a tank (or vat) configured tocontain a resin and including an entrance port and an exit port and aresin circulatory system. The resin circulatory system includes a pairof pumps wherein a first one of the pumps is arranged to extract theresin from the tank through the exit port of the tank, and a second oneof the pumps is arranged to flow the resin (or a fluid or thecombination of the resin and the fluid) into the tank via the entranceport of the tank. In particular, the first pump is configured to extractthe resin from the tank and flow the resin towards a branch pointfluidly coupled to the first pump. A first valve regulates flow of theresin from the branch point to an inlet of a first reservoir and asecond valve regulates flow of the resin from the branch point to afirst confluence point. Resin flow is also regulated from an outlet ofthe first reservoir, in particular a third valve regulates flow of theresin from the outlet of the first reservoir to a second confluencepoint, and a fourth valve regulates flow of the resin from the firstconfluence point to the second confluence point. A second reservoir isconfigured to supply a fluid that includes fresh resin and/or anadditive to the first confluence point, and a second pump is configuredto extract the resin, the fluid, or a combination of the resin and thefluid from the second confluence point and flow the resin, the fluid, orthe combination of the resin, as appropriate, and the fluid into thetank via the entrance port of the tank.

A further embodiment of the invention provides a process for operating avat polymerization apparatus of the kind described above. In thatprocess, the first and third valves are opened and the second and fourthvalves are closed during a first time period, so as to flow resin fromthe tank through the first reservoir and back into the tank. During asecond time period, the first and third valves are closed and the secondand fourth valves are opened so as to flow resin from the tank to thefirst confluence point attached to the second reservoir and flow thecombination of the resin and the fluid into the tank.

Another embodiment of the invention concerns a membrane assembly for a3D printing system. The assembly includes a radiation-transparentflexible membrane and a frame affixed to a perimeter of theradiation-transparent flexible membrane. The frame is configured tostretch the radiation-transparent flexible membrane along a first plane,and includes a lip extending perpendicular to the first plane. The lipis configured to be secured to a bottom rim of a tank sidewall; thus,when the membrane assembly is secured to the bottom of the tanksidewall, it forms a bottom of the tank that contains a photo-curingliquid resin.

In some instances, the membrane assembly includes a tension adjustmentmechanism configured to adjust the tension of the radiation-transparentflexible membrane. A tension sensor (e.g., a strain gauge) may beaffixed to a surface of the radiation-transparent flexible membrane andconfigured to measure a tension of the radiation-transparent flexiblemembrane. In other instances, a tension sensor such as a conductivestrip may be embedded within the radiation-transparent flexible membraneand configured to measure a tension of the radiation-transparentflexible membrane.

Such a tension sensor may be a component of a tank assembly that alsoincludes a tank sidewall, wherein the tension sensor coupled to the tanksidewall and a bottom rim of the tank sidewall includes a groove. Aradiation-transparent flexible membrane may be secured within a framethat includes a lip that engages with the groove of the bottom rim ofthe tank sidewall. The tension sensor may be configured to detect amovement of the radiation-transparent flexible membrane upon a loss oftension of the radiation-transparent flexible membrane.

Still another embodiment of the invention provides an apparatus thatincludes a glass frame assembly having a first frame supporting a glassplate and/or radiation-transparent flexible membrane and including afirst plurality of through holes and a first plurality of magnetizedportions distributed about a surface of the first frame; and a liquidcrystal display (LCD) assembly having a second frame and an LCD. Thesecond frame is configured to hold the LCD and includes a secondplurality of through holes and a second plurality of magnetized portionsdistributed about a surface of the second frame. The pattern in whichthe first plurality of through holes are distributed about the surfaceof the first frame is a mirror image of the pattern in which the secondplurality of through holes are distributed about the surface of thesecond frame, and the pattern in which the first plurality of magnetizedportions are distributed about the surface of the first frame is amirror image of a pattern in which the second plurality of magnetizedportions are distributed about the surface of the second frame. Each ofthe first plurality of magnetized portions is attracted to acorresponding one of the second plurality of magnetized portions suchthat when the first frame is disposed in proximity to the second frame,the surface of the first frame is attracted to and automaticallycontacts the surface of the second frame such that each one of the firstplurality of through holes automatically aligns with a corresponding oneof the second plurality of through holes. In some instances, a gasket isdisposed within or near a boundary region between the surface of thefirst frame and the surface of the second frame. The gasket preventsresin from contacting the region between the glass plate and the LCD.

Another embodiment of the invention provides a 3D printing system havinga tank assembly with a tank sidewall, and a radiation-transparentflexible membrane within a first frame, wherein a bottom rim of the tanksidewall includes a groove and the first frame has a lip that engageswith the groove of the bottom rim of the tank sidewall. The assemblyfurther includes a lighting assembly having a glass plate secured withina second frame; and a liquid crystal display (LCD) secured within athird frame, wherein the second frame is secured to the third frame, andwherein the second frame is configured to displace a portion of theradiation-transparent flexible membrane away from a first plane into asecond plane parallel to the first plane, wherein the first planedefines a region in which the radiation-transparent flexible membranelies absent the displacement of the portion of the radiation-transparentflexible membrane by the second frame.

Such an assembly may also include a base portion configured to supportat least one of the third frame or the LCD and a height adjustmentmechanism disposed between the first frame and the base portion. Theheight adjustment mechanism may be configured to adjust a verticalposition of the first frame with respect to the base portion, and inturn adjust the displacement of the portion of the radiation-transparentflexible membrane with respect to the first plane. Alternatively, thebase portion may be configured to support the first frame and the heightadjustment mechanism disposed between the base portion and at least oneof the third frame or the LCD and configured to adjust a verticalposition of the LCD with respect to the base portion, and in turn adjustthe displacement of the portion of the radiation-transparent flexiblemembrane with respect to the first plane.

Still another embodiment of the invention provides a 3D printing systemhaving a tank assembly and a radiation-transparent flexible membrane.The tank assembly includes a tank sidewall having a bottom rim with agroove. The radiation-transparent flexible membrane is secured in afirst frame that has a lip which engages the groove of the bottom rim ofthe tank sidewall. An LCD is secured within a second frame and isconfigured to displace a portion of the radiation-transparent flexiblemembrane away from a first plane into a second plane parallel to thefirst plane, wherein the first plane defines a region in which theradiation-transparent flexible membrane lies absent the displacement ofthe portion of the radiation-transparent flexible membrane by the secondframe.

These and further embodiments of the invention are described in detailbelow with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A depicts a block diagram of a resin circulatory system for athree-dimensional (3D) printing system, in accordance with oneembodiment of the invention.

FIG. 1B depicts the resin circulatory system of FIG. 1A additionallywith cooling and filtration components, in accordance with oneembodiment of the invention.

FIG. 1C depicts the resin circulatory system of FIG. 1A additionallywith a controller, in accordance with one embodiment of the invention.

FIG. 2 depicts a perspective view of a membrane assembly for a 3Dprinting system, in accordance with one embodiment of the invention.

FIG. 3 depicts a perspective view of a tank sidewall for a 3D printingsystem, in accordance with one embodiment of the invention.

FIGS. 4A and 4B depict cross-sectional views of the membrane assemblyand the tank sidewall so as to describe a process in which the membraneassembly is secured to the bottom rim of the tank sidewall, inaccordance with one embodiment of the invention.

FIGS. 5A and 5B depict perspective views of a glass plate assembly and aliquid crystal display (LCD) assembly so as to describe a mechanism inwhich the glass plate assembly is secured to the LCD assembly, inaccordance with one embodiment of the invention.

FIG. 5C depicts a cross-sectional view along line I-I of FIG. 5B, inaccordance with one embodiment of the invention.

FIGS. 6A and 6B depict cross-sectional views of components of a 3Dprinting system so as to describe a process in which the 3D printingsystem is assembled, in accordance with one embodiment of the invention.

FIG. 6C depicts an enlarged cross-sectional view showing a portion ofthe membrane displaced from its rest plane, in accordance with oneembodiment of the invention.

FIG. 6D depicts a cross-sectional view of a 3D printing system with aheight adjustment mechanism configured to adjust the position of themembrane with respect to its rest plane, in accordance with oneembodiment of the invention.

FIG. 6E depicts a cross-sectional view of a 3D printing system with analternative and/or additional height adjustment mechanism configured toadjust the position of the membrane with respect to its rest plane, inaccordance with one embodiment of the invention.

FIG. 6F depicts a cross-sectional view of a 3D printing system withoutthe optional glass plate between the membrane and the LCD, in accordancewith one embodiment of the invention.

FIG. 6G depicts a cross-sectional view of a 3D printing system withoutdisplacement in the membrane, in accordance with one embodiment of theinvention.

FIG. 6H depicts a cross-sectional view of another 3D printing systemwithout displacement in the membrane, in accordance with one embodimentof the invention.

FIGS. 7A-7C depict cross-sectional views of a 3D printing system duringa 3D printing process, in accordance with one embodiment of theinvention.

FIG. 7D shows an enlarged view of FIG. 7C, depicting the membrane beingdisplaced due to the vertical translation of the partially formedobject, in accordance with one embodiment of the invention.

FIG. 7E depicts a state of the membrane shortly after the illustrationof FIG. 7D, in which the membrane has relaxed back onto the surface ofthe glass plate, in accordance with one embodiment of the invention.

FIG. 8A depicts a cross-sectional view of a portion of the membraneassembly that shows a tension adjustment mechanism, in accordance withone embodiment of the invention.

FIG. 8B depicts a cross-sectional view of a portion of the membraneassembly that shows a tension sensor, in accordance with one embodimentof the invention.

FIG. 8C depicts a cross-sectional view of a portion of the membraneassembly that shows an alternative or additional tension sensor, inaccordance with one embodiment of the invention.

FIG. 8D depicts a cross-sectional view of a portion of a tank assemblythat shows an alternative or additional tension sensor, in accordancewith one embodiment of the invention.

FIG. 9 depicts components of a computer system in which computerreadable instructions instantiating the methods of the present inventionmay be stored and executed.

DETAILED DESCRIPTION

The present invention relates to systems and methods of additivemanufacturing in which a photo-sensitive resin is cured through exposureto radiation when fabricating an object, and in some embodiments, tomethods and systems for cooling the photo-sensitive resin throughdisplacement of the resin with respect to a build area of the object,and in some embodiments, to a membrane assembly, and in someembodiments, to a mechanism for self-aligning a glass plate frame to aliquid crystal display (LCD) frame, and in some embodiments, to atension sensor integrated with a the membrane assembly, and in someembodiments, to a tension sensor integrated with a tank assembly, and insome embodiments to a tension adjustment mechanism embedded within themembrane assembly, and in some embodiments, to a tension adjustmentmechanism external to the membrane assembly, and in some embodiments, toa three-dimensional printing system with a membrane displaced from itsrest plane

FIG. 1A depicts a block diagram of a resin circulatory system for athree-dimensional (3D) printing system. Tank 102 (also labelled as“VAT”) is configured to contain a photo-sensitive liquid resin that isused to form one or more objects during a 3D printing process. Before,during or after the 3D printing of the object within tank 102, the resincirculatory system may be configured to extract resin from tank 102 viaexit port 103 of the tank and introduce resin into tank 102 via entranceport 101 of the tank. One or more of the following tasks may beaccomplished via such a resin circulatory system, including cooling theresin, draining resin that has been depleted of photo-curing polymers,filtering impurities (e.g., including fragments of cured polymer) fromthe resin, supplying fresh resin to the tank, and introducing additivesto the resin.

The resin circulatory system may include pump 104 (also labelled as“P1”) that is configured to extract the resin from tank 102 through exitport 103, and flow the resin towards branch point 113. It is understoodthat tubing (indicated in solid-dashed line) may be used to fluidlycouple any two components depicted in FIGS. 1A-1C, such as pump 104 andtank 102.

Branch point 113 may be fluidly coupled to pump 104, valve 112 (alsolabelled as “V1”) and valve 114. Valve 112 may regulate a flow of theresin from branch point 113 to an inlet of reservoir 108. In oneembodiment, reservoir 108 may be 5 Liters in volume. In operation,reservoir 108 may be partially or fully filled with resin. Drain 109 maybe disposed on a bottom portion of reservoir 108 and may be used todrain the resin when necessary to dispose of resin that has beendepleted of photo-curing polymers.

Valve 114 (also labelled as “V2”) may regulate a flow of the resin frombranch point 113 to confluence point 111. Resin flowing from valve 114and a fluid flowing from reservoir 110 may mix at confluence point 111before flowing towards valve 118. The fluid may comprise fresh (i.e.,not previously used) resin, an additive or another liquid. In oneembodiment, reservoir 110 may be 1 Liter in volume. Valve 116 (alsolabelled as “V3”) may regulate a flow of the resin from an outlet ofreservoir 108 to confluence point 117. Valve 118 (also labelled as “V4”)may regulate a flow of the resin from confluence point 111 to confluencepoint 117. Pump 106 may be configured to extract the resin, the fluid ora combination of the resin and the fluid from confluence point 117 andflow the resin, the fluid or the combination of the resin and the fluidinto tank 102 via entrance port 101.

FIG. 1B depicts the resin circulatory system of FIG. 1A additionallywith cooling and filtration components. Resin may be cooled withinreservoir 108 via cooling jacket 120 and/or cooled within tubing viacooling sleeve 122. The location of cooling sleeve 122 as shown in FIG.1B is for illustrative purposes only, and it is understood that coolingsleeve 122 may be located along any section of tubing fluidly couplingexit port 103 to entrance port 101.

Cooling of resin may be necessary due to an exothermic reaction whichtakes place when resin is cured in tank 102. If cooling of resin is notperformed, resin within tank 102 may heat up over time, leading to anunintended curing of resin (and potentially a loss of resolution in theprinting process). Additionally, filter 124, disposed along a section oftubing, may be used to remove particulates, impurities and/or othercontaminants from the recirculating resin. The location of filter 124 asshown in FIG. 1B is for illustrative purposes only, and it is understoodthat filter 124 may be located along any section of tubing fluidlycoupling exit port 103 to entrance port 101.

FIG. 1C depicts the resin circulatory system of FIG. 1A additionallywith controller 126. Controller 126 may be communicatively coupled toone or more of pumps 104 and 106; and valves 112, 114, 116 and 118.Controller 126 may control a pumping speed of pumps 104 and 106, as wellas the degree to which one or more of valves 112, 114, 116 and 118 areopen or closed. For clarity of discussion, a valve being “open” refersto the state in which a fluid is able to flow through the valve, whereasa valve being “closed” refers to the state in which a fluid is not ableto flow through the valve. While the use of controller 126 to controlthe operational state of one or more of pumps 104 and 106; and valves112, 114, 116 and 118 in accordance with a computer program iscontemplated, it is certainly possible that one or more of pumps 104 and106; and valves 112, 114, 116 and 118 can also be manually controlled bya human operator.

Several modes of operation of the resin circulatory system arecontemplated. In a first mode, valves 112 and 116 are open and valves114 and 118 are closed, causing pumps 104 and 106 to circulate resinfrom tank 102 through reservoir 108 and optionally, back into tank 102.Operation in accordance with the first mode may occur in order to cool,filter and/or drain (i.e., remove) the resin.

In a second mode, valves 112 and 116 are closed and valves 114 and 118are open, causing pumps 104 and 106 to circulate resin from tank 102through confluence point 111 and back into tank 102. Operation inaccordance with the second mode may occur in order to inject fluid fromreservoir 110 into the resin from tank 102. As mentioned above, thefluid may include fresh resin, an additive or another liquid.

In a third mode, pump 104 may be turned off, pump 106 may be turned on,valves 112, 114 and 116 may be closed and valve 118 may be open in orderto fill an initially empty tank 102 with resin from reservoir 110 (e.g.,as part of an initialization procedure).

In a fourth mode, valves 112, 114, 116 and 118 may all be fully (orpartially) open. The fourth mode is functionally equivalent to a mixtureof the first and second modes.

In FIGS. 1A-1C, valves 112 and 116 have also been labelled as “NO”(shorthand for “normally open”) and valves 114 and 118 have also beenlabelled as “NC” (shorthand for “normally closed”). As such, it iscontemplated that the resin circulatory system typically operates in thefirst mode and occasionally switches to the second mode of operation(although the third and fourth modes of operation are possible).

It is understood that aspects of one or more of the resin circulatorysystems depicted in FIGS. 1A-1C may be incorporated into one resincirculatory system. Aspects of the resin circulatory system have beendepicted separately in FIGS. 1A-1C for ease of illustration anddescription.

FIG. 2 depicts a perspective view of membrane assembly 200 for a 3Dprinting system. Membrane assembly 200 may include radiation-transparentflexible membrane 204 whose perimeter is secured to frame 202. Frame 202may be configured to stretch membrane 204 along a first plane. Frame 202may comprise lip 206 that extends in a direction perpendicular to thefirst plane. Lip 206 may be secured to a bottom rim of a tank sidewall(as depicted in FIG. 3). Membrane assembly 200, when secured to thebottom rim of the tank sidewall, forms a bottom of a tank configured tocontain a photo-curing liquid resin. In FIG. 2, frame 202 is depicted tohave a rectangular shape. It is understood that other shapes for frame202 are possible, including square, oval, circular, etc.

FIG. 3 depicts a perspective view of tank sidewall 300 for a 3D printingsystem. The tank sidewall 300 includes bottom rim 302 with groove 304.Lip 206 of frame 202 may be inserted within groove 304 so as to securemembrane assembly 200 onto the base of tank sidewall 300. It isunderstood that the shape and dimensions of tank sidewall 300 must matchthe shape and dimensions of frame 202. For instance, if frame 202 wererectangular, a tank sidewall 300 must also be rectangular (i.e., whenviewed from above).

FIGS. 4A and 4B depict cross-sectional views of membrane assembly 200(with frame 202 and membrane 204) and tank sidewall 300 so as todescribe a process in which membrane assembly 200 is secured to bottomrim 302 of tank sidewall 300. FIG. 4A depicts lip 206 of frame 202aligned under groove 304 of tank sidewall 300. FIG. 4B depicts lip 206of frame 202 inserted within groove 304 of tank sidewall 300. Lip 206and groove 304 may interlock with one another (e.g., in a snap-fitattachment), may snugly fit so that surfaces of lip 206 and groove 304contact one another (e.g., in a friction-fit attachment), etc. In oneembodiment, membrane assembly 200 may be a “consumable” product, in thatit is disposed of or refurbished at the end of its useful lifetime. Assuch, membrane assembly 200 may play a similar role as printercartridges in a printer; razor blades in a razor; etc.

FIGS. 5A and 5B depict perspective views of frame assembly 500 and LCDassembly 501 so as to describe a mechanism in which frame assembly 500may be secured to LCD assembly 501. Frame assembly 500 may include frame504 and glass plate 502, in which frame 504 is configured to hold glassplate 502. In other embodiments, the frame assembly 500 may support aradiation-transparent flexible membrane, as discussed above, instead ofor in addition to a glass plate. Frame 504 may comprise through holes510 a and magnetized portions 512 a distributed about a bottom surfaceof frame 504. LCD assembly 501 may include frame 508 and LCD 506, inwhich frame 508 is configured to hold LCD 506. Frame 508 may comprisethrough holes 510 b and magnetized portions 512 b distributed about atop surface of frame 508.

As depicted in FIG. 5A, a pattern in which through holes 510 a aredistributed about the bottom surface of frame 504 may be a mirror imageof a pattern in which through holes 510 b are distributed about the topsurface of frame 508. As further depicted in FIG. 5A, a pattern in whichmagnetized portions 512 a are distributed about the bottom surface ofthe frame 504 may be a mirror image of a pattern in which magnetizedportions 512 b are distributed about the top surface of frame 508. Eachone of magnetized portions 512 a may be attracted to a corresponding oneof magnetized portions 512 b such that when frame 504 is disposed in aproximity of frame 508, the bottom surface of the frame 504automatically contacts the top surface of frame 508, and each one of thethrough holes 510 a automatically aligns with a corresponding one ofthrough holes 510 b. Gasket 514 may be disposed at or near a perimeterof LCD 506. The purpose of gasket 514 will be explained below in FIG.5C.

FIG. 5B depicts a perspective view of frame 504 affixed to LCD frame508. Frame 504 surrounds glass plate 502 and/or a radiation-transparentflexible membrane. LCD 506 is not visible in FIG. 5B and is locateddirectly beneath glass panel 502. It is understood that small screws orpins may be inserted through aligned pairs of through holes 510 a and510 b. Openings for such screws or pins may be located in a bottomsurface of frame 508 (not depicted).

FIG. 5C depicts a cross-sectional view along line I-I of FIG. 5B. Asshown in FIG. 5C, frame assembly 500 is affixed to the LCD assembly 501.More particularly, a bottom surface of frame 504 contacts a top surfaceof frame 508, and glass plate 502 and/or a radiation-transparentflexible membrane is disposed above LCD 506. Gasket 514 may be disposedwithin or near a boundary region between the bottom surface of frame 504and the top surface of frame 508. In the event that resin (or anotherfluid) is able to penetrate the boundary region between the bottomsurface of frame 504 and the top surface of frame 508, gasket 514 mayprevent the resin from flowing between LCD 506 and glass plate 502(which may lead to undesirable distortion in images projected from LCD506).

As described above, magnets (or magnetized portions of the frames) wereused to automatically align through holes 510 a with through holes 510b. In addition or alternatively, grooves (e.g., saw tooth grooves)disposed on both the bottom surface of frame 504 and the top surface offrame 508 (and particularly grooves in the bottom surface that arecomplementary to grooves in the top surface) may also be used as aself-alignment mechanism.

FIGS. 6A and 6B depict cross-sectional views of components of a 3Dprinting system so as to describe a process to assemble the 3D printingsystem. FIGS. 6A and 6B depict a tank assembly 600 (comprising tanksidewall 300 and membrane assembly 200) being affixed to a lightingassembly 601 (comprising glass plate 502, frame 504, LCD 506, frame 508and base portion 602). At least one of LCD 506 or frame 508 may besupported on base portion 602. It is noted that glass plate 502 is anoptional component and some embodiments (as described below) may notinclude glass plate 502. In one embodiment, the clearance betweenmembrane 204 and base portion 602 may be less than the combined heightof glass plate 502 and LCD 506. As such, when tank assembly 600 isaffixed to lighting assembly 601, glass plate 502 may displace a portionof membrane 204 away from a first plane and into a second plane parallelto the first plane. The first plane may define a region in whichmembrane 204 is disposed prior to tank assembly 600 being affixed tolighting assembly 601, and may also be called the “rest plane” ofmembrane 204.

FIG. 6C depicts an enlarged cross-sectional view showing a portion ofmembrane 204 being disposed in plane 605, having been displaced fromplane 604 into plane 605 by glass panel 502 and/or frame 504. Thedisplacement in membrane 204 may increase a tension of membrane 204,which may be advantageous for the 3D printing system, as described belowin FIGS. 7D and 7E. It is noted that for the embodiment depicted inFIGS. 6A-6C, it is important for the dimensions (i.e., length and width)of frames 504 and 508 to be smaller than the dimensions (i.e., lengthand width) of frame 202, so that frames 504 and 508 can be inserted intothe region surrounded by frame 202.

FIG. 6D depicts a cross-sectional view of a 3D printing system withheight adjustment mechanism 606 disposed between frame 202 and baseportion 602. Height adjustment mechanism 606 may be configured to adjusta vertical position of frame 202 with respect to base portion 602, andin turn adjust the displacement of the portion of membrane 204 withrespect to plane 604 (i.e., plane 604 depicted in FIG. 6C). Heightadjustment mechanism 606 may include one or more of posts, rails,tracks, stepper motors, piezo transducers, or other means. It is notedthat height adjustment mechanism 606 may also be called a “tensionadjustment mechanism”, as adjusting the displacement of membrane 204 hasthe associated effect of adjusting the tension of membrane 204.

FIG. 6E depicts a cross-sectional view of a 3D printing system withheight adjustment mechanism 608 disposed between base portion 602 and atleast one of LCD 506 or frame 508. Height adjustment mechanism 608 maybe configured to adjust a vertical position of LCD 506 with respect tobase portion 602, and in turn adjust the displacement of the portion ofmembrane 204 with respect to plane 604 (i.e., plane 604 depicted in FIG.6C). Similarly, height adjustment mechanism 608 may be called a “tensionadjustment mechanism”. FIG. 6F depicts a cross-sectional view of a 3Dprinting system without the optional glass plate 502 between membrane204 and LCD panel 506, in accordance with one embodiment of theinvention. The clearance between membrane 204 and base portion 602 maybe less than the height of LCD 506, similarly causing LCD 506 (or frame508) to displace membrane 204 from a first plane into a second plane,and increasing the tension of membrane 204. It is noted that for theembodiment depicted in FIG. 6F, it is likewise important for thedimensions (i.e., length and width) of frame 508 to be smaller than thedimensions (i.e., length and width) of frame 202, so that frame 508 canbe inserted into the region surrounded by frame 202.

FIG. 6G depicts a cross-sectional view of an embodiment of a 3D printingsystem without displacement in membrane 204, in accordance with oneembodiment of the invention. In FIG. 6G, the dimensions of frame 508(i.e., frame securing LCD 506) are similar to the dimensions of frame202 (i.e., frame securing membrane 204) so that frame 202 rests uponframe 508. Neither frame 508 nor LCD 506 displace membrane 204 in theembodiment of FIG. 6G.

FIG. 6H depicts a cross-sectional view of another embodiment of a 3Dprinting system without displacement in membrane 204. In FIG. 6H, thedimensions of frame 508 (i.e., frame securing LCD 506) and frame 504(i.e., frame securing glass plate 502) are similar to the dimensions offrame 202 (i.e., frame securing membrane 204) so that frame 202 restsupon frame 504 and frame 504 rests upon frame 508. Neither frame 504 norglass 502 displace membrane 204 in the embodiment of FIG. 6H.

FIGS. 7A-7C depict cross-sectional views of a 3D printing system duringa 3D printing process. In FIG. 7A, photo-curing liquid resin 702 iscontained within the tank assembly. Partially formed object 706 issecured to extraction plate 704. Subsequent to FIG. 7A and prior to FIG.7B, radiation is emitted from LCD 506 which forms an image in the regionbetween the partially formed object 706 and membrane 204. The imageselectively cures resin 702 and forms a new layer 708 of partiallyformed object 706, as depicted in FIG. 7B. FIG. 7C depicts extractionplate 704 being raised vertically by a height adjusting means (notdepicted), causing partially formed object 706 (along with new layer708) to be lifted within resin 702. At least initially, new layer 708may partially adhere to membrane 204 so that when new layer 708 israised by extraction plate 704, membrane 204 may be pulled (slightly)away from the surface of glass plate 502. FIG. 7D shows an enlarged viewof FIG. 7C. The small downward arrows in FIG. 7D represent the reflexiveforce that draws membrane 204 back towards glass plate 502. As mentionedearlier, displacement of membrane 204 by glass plate 502 (i.e., awayfrom the rest plane of membrane 204) increases the tension on membrane204. The increased tension beneficially increases the reflexive forceand decreases the time taken by membrane 204 to reach the state depictedin FIG. 7E, in which the membrane is once again disposed on the surfaceof glass plate 502.

FIG. 8A depicts a cross-sectional view of a portion of membrane assembly200, that shows tension adjustment mechanism 804, 806 embedded withinthe membrane assembly 200. Anchor 800 may be used to anchor a perimeterof membrane 204 in a stationary manner with respect to frame 202. Cavity802 within membrane frame 202 allows for displacement of membrane 204(as drawn in FIG. 8A, displacement in the direction perpendicular to aplane in which membrane 204 extends). Membrane engagement member 804 maybe configured to impart a force onto the surface of membrane 204 so asto increase or decrease a tension of membrane 204. Screw 806 may abutagainst membrane engagement member 804. The turning of screw 806 aboutan axis of the screw may adjust a position of membrane engagement member804 with respect to frame 202 and in turn adjust the tension of membrane204. Elements 804 and 806 are only one embodiment of a tensionadjustment means and it is understood that other tension adjustmentmeans are possible, such as a mechanism that adjusts the force impartedon membrane 204 in a direction parallel to the plane in which membrane204 lies.

FIG. 8B depicts a cross-sectional view of a portion of membrane assembly200 that shows tension sensor 808 a (for measuring a tension of themembrane) affixed to a surface of membrane 204. More specifically,tension sensor 808 a may be affixed to a bottom surface of membrane 204so that tension sensor 808 a is not exposed to the resin which contactsthe top surface of membrane 204 (i.e., when the 3D printing system is inuse). Furthermore, tension sensor 808 a may be located in a region ofmembrane 204 that does not block radiation from LCD 506 (i.e., in theperipheral regions). Electrical wires 810 a and 810 b may beelectrically connected to tension sensor 808 a so as to allowmeasurement of the membrane tension at a location remote from membrane204. In one embodiment, tension sensor 808 a may comprise a strain gaugewith a meandering structure that is affixed to the surface of membrane204. While not depicted, wire 810 may be communicatively coupled to adisplay (where the tension level may be displayed to a human operator),or to a controller (such as controller 126).

A feedback control algorithm may be employed by controller 126. Forexample, controller 126 may measure the tension of membrane 204 usingtension sensor 808 a, compare the measured tension to a desired tensionvalue, provide control signals to height adjustment mechanism 606, 608or tension adjustment mechanism 804, 806 so as to adjust the tension ofmembrane 204, measure the new tension of membrane 204 using tensionsensor 808 a, and so on until the desired tension value is reached(within some defined tolerance limit).

FIG. 8C depicts a cross-sectional view of a portion of membrane assembly200 that shows an alternative or additional tension sensor 808 b (formeasuring a tension of the membrane) embedded within membrane 204. Liketension sensor 808 a, tension sensor 808 b may be located in a region ofmembrane 204 that does not block radiation from LCD 506 (i.e., in theperipheral regions). Electrical wires 810 a and 810 b may beelectrically connected to tension sensor 808 b so as to allowmeasurement of the membrane tension at a location remote from membrane204. In one embodiment, tension sensor 808 b may be a conductive strip.Stretching or a relaxation of membrane 204 may strain or deform theconductive strip and alter an electrical current flowing through theconductive strip. In turn, a measurement of the electrical current maybe mapped or converted into a tension value of membrane 204.

FIG. 8D depicts a cross-sectional view of a portion of tank assembly 600that shows an alternative or additional tension sensor 808 c coupled totank sidewall 300. Tension sensor 808 c may be configured to detect amovement of membrane 204 upon loss of tension of membrane 204 (e.g.,when a tear develops in membrane 204). One advantage of tension sensor808 c being coupled to (or integrated with) tank sidewall 300 instead ofto membrane assembly 200 (as described in FIGS. 8B and 8C) is thattension sensor 808 c is located on a “permanent” component, as opposedto the “consumable” membrane assembly 200. Tension sensor 808 c may onlybe infrequently replaced whenever it reaches its useful lifetime,whereas tension sensors 808 a, 808 b may be replaced whenever membraneassembly 200 is replaced. In other words, tension sensors of membraneassembly 200 may be replaced not due to necessity, but replaced becausethe entire membrane assembly is being replaced.

While one or more of tension sensors 808 a, 808 b, 808 c may be used tocalibrate the tension of membrane 204, other calibration routines may beemployed that do not require the use of tension sensors. For example,cameras or other imaging equipment may be used to evaluate a teststructure (e.g., with various geometries—lines, holes, planes, etc.)under construction in tank assembly 600. Images from the cameras may becompared against prestored images of a properly fabricated teststructure (or a computer rendering of a simulated version of the teststructure). Variations like non-uniform edges, holes that are not fullyopen, etc. may be identified in the test structure under fabrication,and the tension of membrane 204 may be adjusted in response thereto(using one or more of the above-described tension adjustment mechanisms)until the test structure comports with the desired geometries withinsome tolerance level.

In one embodiment, a plurality of tension sensors may be located ondifferent portions of membrane 204 to obtain different “local” readings.The local readings may then be combined to arrive at one “global”estimate of the membrane tension. In one embodiment, an average of thelocal readings may be computed, while in another embodiment, a linearcombination of the local readings may be computed (e.g., using differentcalibration weights for each tension sensor).

As is apparent from the foregoing discussion, aspects of the presentinvention involve the use of various computer systems and computerreadable storage media having computer-readable instructions storedthereon. FIG. 9 provides an example of a system 900 that may berepresentative of any of the computing systems (e.g., controller 126)discussed herein. Examples of system 900 may include a smartphone, adesktop, a laptop, a mainframe computer, an embedded system, etc. Note,not all of the various computer systems have all of the features ofsystem 900. For example, certain ones of the computer systems discussedabove may not include a display inasmuch as the display function may beprovided by a client computer communicatively coupled to the computersystem or a display function may be unnecessary. Such details are notcritical to the present invention.

System 900 includes a bus 902 or other communication mechanism forcommunicating information, and a processor 904 coupled with the bus 902for processing information. Computer system 900 also includes a mainmemory 906, such as a random access memory (RAM) or other dynamicstorage device, coupled to the bus 902 for storing information andinstructions to be executed by processor 904. Main memory 906 also maybe used for storing temporary variables or other intermediateinformation during execution of instructions to be executed by processor904. Computer system 900 further includes a read only memory (ROM) 908or other static storage device coupled to the bus 902 for storing staticinformation and instructions for the processor 904. A storage device910, for example a hard disk, flash memory-based storage medium, orother storage medium from which processor 904 can read, is provided andcoupled to the bus 902 for storing information and instructions (e.g.,operating systems, applications programs and the like).

Computer system 900 may be coupled via the bus 902 to a display 912,such as a flat panel display, for displaying information to a computeruser. An input device 914, such as a keyboard including alphanumeric andother keys, may be coupled to the bus 902 for communicating informationand command selections to the processor 904. Another type of user inputdevice is cursor control device 916, such as a mouse, a trackpad, orsimilar input device for communicating direction information and commandselections to processor 904 and for controlling cursor movement on thedisplay 912. Other user interface devices, such as microphones,speakers, etc. are not shown in detail but may be involved with thereceipt of user input and/or presentation of output.

The processes referred to herein may be implemented by processor 904executing appropriate sequences of computer-readable instructionscontained in main memory 906. Such instructions may be read into mainmemory 906 from another computer-readable medium, such as storage device910, and execution of the sequences of instructions contained in themain memory 906 causes the processor 904 to perform the associatedactions. In alternative embodiments, hard-wired circuitry orfirmware-controlled processing units may be used in place of or incombination with processor 904 and its associated computer softwareinstructions to implement the invention. The computer-readableinstructions may be rendered in any computer language.

In general, all of the above process descriptions are meant to encompassany series of logical steps performed in a sequence to accomplish agiven purpose, which is the hallmark of any computer-executableapplication. Unless specifically stated otherwise, it should beappreciated that throughout the description of the present invention,use of terms such as “processing”, “computing”, “calculating”,“determining”, “displaying”, “receiving”, “transmitting” or the like,refer to the action and processes of an appropriately programmedcomputer system, such as computer system 900 or similar electroniccomputing device, that manipulates and transforms data represented asphysical (electronic) quantities within its registers and memories intoother data similarly represented as physical quantities within itsmemories or registers or other such information storage, transmission ordisplay devices.

Computer system 900 also includes a communication interface 918 coupledto the bus 902. Communication interface 918 may provide a two-way datacommunication channel with a computer network, which providesconnectivity to and among the various computer systems discussed above.For example, communication interface 918 may be a local area network(LAN) card to provide a data communication connection to a compatibleLAN, which itself is communicatively coupled to the Internet through oneor more Internet service provider networks. The precise details of suchcommunication paths are not critical to the present invention. What isimportant is that computer system 900 can send and receive messages anddata through the communication interface 918 and in that way communicatewith hosts accessible via the Internet. It is noted that the componentsof system 900 may be located in a single device or located in aplurality of physically and/or geographically distributed devices.

Thus, a three-dimensional printing system has been described. It is tobe understood that the above-description is intended to be illustrative,and not restrictive. Many other embodiments will be apparent to those ofskill in the art upon reviewing the above description. The scope of theinvention should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled.

What is claimed is:
 1. A membrane assembly for a three-dimensionalprinting system, comprising: a radiation-transparent flexible membrane;and a frame configured to stretch the radiation-transparent flexiblemembrane along a first plane, wherein the frame comprises a top planarsurface that extends parallel to the first plane, a bottom planarsurface that extends parallel to the first plane, an inner side surfacedisposed between the top and bottom planar surfaces, and a lip extendingfrom the top planar surface in a direction perpendicular to the firstplane, and spaced apart from the inner side surface, and wherein aperimeter of the radiation-transparent flexible membrane contacts theinner side surface of the frame.
 2. The membrane assembly of claim 1,wherein the frame further comprises an outer side surface disposedbetween the top and bottom planar surfaces, and wherein the lip isfurther spaced apart from the outer side surface of the frame.
 3. Themembrane assembly of claim 1, wherein a distance that the lip is setbackfrom the inner side surface of the frame is equal to a distance that thelip is setback from the outter side surface of the frame.
 4. Themembrane assembly of claim 1, further comprising a tension adjustmentmechanism coupled to the radiation-transparent flexible membrane andconfigured to adjust a tension of the radiation-transparent flexiblemembrane.
 5. The membrane assembly of claim 1, further comprising atension sensor affixed to a surface of the radiation-transparentflexible membrane and configured to measure a tension of theradiation-transparent flexible membrane.
 6. The membrane assembly ofclaim 5, wherein the tension sensor comprises a strain gauge affixed tothe surface of the radiation-transparent flexible membrane.
 7. Themembrane assembly of claim 1, further comprising a tension sensorembedded within the radiation-transparent flexible membrane andconfigured to measure a tension of the radiation-transparent flexiblemembrane.
 8. The membrane assembly of claim 7, wherein the tensionsensor comprises a conductive strip embedded within theradiation-transparent flexible membrane.